Fabric softener device for in-dryer use

ABSTRACT

A system for the softening or other treatment of fabric articles is provided which comprises a vented bag comprising a fastening system and flexible sheet releasably impregnated with an effective amount of a liquid fabric-treatment composition.

FIELD OF THE INVENTION

[0001] The present invention provides a fabric-treatment systemcomprising a vented plastic heat-resistant bag having an opening with afastening system that enables closure of the bag, so as to enclose aflexible sheet impregnated with a liquid fabric-treating formulation, aswell as a method for use of the bag and the related sheet. The inventionparticularly relates to a method for use of the fabric-treatment deviceto soften and/or otherwise treat fabrics, such as articles of clothing.More particularly, the present invention relates to a method of fabricsoftening and/or treatment that can be carried out in a rotary clothesdryer.

BACKGROUND OF THE INVENTION

[0002] Certain chemical compounds have long been known in the art topossess the desired quality of imparting softness to textile fabrics.The quality of “softness” or being “soft” is well defined in the art,and, as used herein, means that quality of the treated fabric wherebyits handle or texture is smooth, pliable, and fluffy, and not rough orscratchy to the touch. Known generally as “fabric softeners,” thesecompounds have long been used by homemakers in the laundry, and by thetextile industry to soften a finished fabric.

[0003] Additionally, many of these compounds act as antistatic agents toreduce the “static cling” of the treated fabrics. Static cling isgenerally the phenomenon of a fabric adhering to another object or toparts of itself as a result of static electrical charges induced on thesurface of the fabric. It can also cause the adherence of lint, dust,and other undesired substances to the fabric. It is noticeably presentin unsoftened fabrics that are freshly washed and dried in an automatichot air dryer. By softening and reducing the static cling of a fabric,it is more comfortable when worn. Such treated fabrics additionally areeasier to iron, and have fewer hard-to-iron wrinkles.

[0004] Perhaps the most common fabric softeners and anti-static agentsknown in the art are cationic compounds, especially amines suchquaternary ammonium and imidazolinium salts. These compounds are widelymarketed for home use in the form of liquid emulsions. They must beadded to the laundry in the rinse cycle, not the wash cycle, becausecationic fabric conditioners interact with anionic substances present inlaundry detergents such as anionic surfactants and builder salts,thereby rendering both relatively ineffective. A commercial fabricconditioner of this type is Downy® (The Proctor & Gamble Company,Cincinnati, Ohio).

[0005] “Another method of softening fabrics involves the utilization ofimpregnated nonwoven dry fabric softener sheets that are added to thedryer along with damp (wet) laundry. The ingredients are releasedlargely in a nonuniform manner from the dry sheet into the laundry bythe abrasive action of tumbling in contact with the laundry, moisturefrom the laundry and the heat of the dryer. In general, the compositioncoated on these is sheets is composed of cationic softening agents,antistatic agents, dispersing ingredients to help provide a more uniformingredient release and fragrance. A commercial dryer sheet of this typeis Bounce@ (The Proctor & Gamble Company, Cincinnati, Ohio). Thedisadvantage with these dryer fabric softener sheets is their relativepoor softening ability versus the liquid softeners that totallypenetrate the laundry fabrics in the last rinse of the washing machinecycle.

[0006] It has previously been impossible to attain the benefits of aliquid fabric softener, i.e., greater softening ability anddispersibility, in the dryer using the dryer sheets. Moreover, usingliquid fabric softeners in the washing machine last rinse cycle requireall the articles in that laundry load to be softened. In some instances,the user may desire to control the softening of the clothing, in whichcase, the user must divide the laundry into those articles they desireto be softened and those they do not. This results in inconvenientexpenditures of time in creating additional wash loads and drying time.

[0007] It is therefore an object of the invention to provide a method ofsoftening fabric articles in the home automatic dryer with liquid fabricsoftener ingredients resulting in superior softening ability. It is afurther object of the invention to provide a method of softening fabricarticles without having to divide articles of clothing into multiplegroups according to the softening and or treatment desired, thusincurring such inconveniences and disadvantages mentioned above.Additional objects of the present invention will become readily apparentto persons skilled in the art from the following discussion.”

SUMMARY OF THE INVENTION

[0008] The present invention provides a fabric-treatment system thatimparts softening, antistatic and/or other desirable properties tolaundered, i.e., moistened (wet), fabric articles. The fabric treatmentsystem of the present invention comprises a bag sized for containmentand treatment of a moistened fabric article which bag comprises anopening having a reversible fastening system. The bag is heat resistantand comprises means such as pores, holes, slits, and the like, to allowescape of the moisture. These moisture releasing means will becollectively referred to as “vents” herein. The system further comprisesa flexible, textile sheet impregnated or coated with an effectivefabric-treatment formulation. Preferably, the fabric-treatmentformulation comprises a fabric softening agent or other fabricconditioning or treating agent, an organic solvent, a dispersing agent,and water. The fabric treatment formulation further comprises asurfactant to enhance the delivery of the formulation to the fabricarticles. The present flexible sheets are dimensionally stable, so thatthey can be readily dispensed by the user and added to the bag of thepresent invention in discrete units, along with moistened clothing orother fabric articles to be treated.

[0009] Thus, it is preferred that the fabric-treatment formulation ofthe present invention is a gelled or thickened liquid comprising (a) aneffective amount of a dispersing agent; (b) a liquid vehicle selectedfrom the group consisting of water, a water-miscible organic solvent andmixtures thereof; (c) at least one fabric treatment agent; and (d) asurfactant. The fabric-treatment formulation of the present invention isreleased from the sheet upon physical contact with the fabric articles,e.g., as when the fabric articles and the sheet are tumbled together inthe bag.

[0010] The present invention also includes a method for depositingfabric treatment agents, such as softening agents, on wet fabrics in arotary hot air dryer. In this embodiment of the invention, the methodcomprises placing one or more wet fabric articles and a suitably sized,impregnated, flexible sheet into the bag, closing the bag, and thensubjecting the bag to an amount of agitation and/or heat effective torelease the fabric-treatment formulation from the flexible sheet uponcontacting the fabric articles. The sheet “tumbles” among the fabricarticles, thus dispersing the fabric treatment composition evenly ontothem. Thus contacted, the fabric articles are softened or otherwisetreated by the formulation and dried as the moisture escapes via thevents in the bag. In a preferred aspect of the invention, the closedbag, containing the flexible sheet and the moistened fabric(s), can beplaced in a rotary hot air clothes dryer to provide the effective amountof heat and/or agitation, or tumbling. As used herein, the term “dryer”refers to a rotary hot air dryer, which tumbles the clothes in a drumwith hot air, usually at a temperature of about 40°-90° C., preferablyat about 50°-95° C., for preselected periods of time. For example, about15-45 minutes of tumbling are sufficient to release the fabric-treatingcomposition from the sheet interior surface of the bag at thesetemperatures and to dry the fabric articles. The term “fabrics” or“fabric articles” encompasses not only clothing, but other items whichare commonly laundered, including sheets, draperies, rugs, upholsterycoverings, towels and the like.

[0011] Thus, the present invention provides a method for depositingfabric treatment agents such as softening agents on fabrics comprising(a) placing a wet fabric article in the aforesaid ventedfabric-treatment bag along with the flexible sheet impregnated with thefabric-treatment formulation; (b) sealing the bag; and (c) tumbling thesealed bag and its contents in a dryer at a temperature effective torelease the fabric-treatment composition and for a time effective tocontact an effective amount of said released fabric-treatmentcomposition with said fabric, so as to soften or otherwise treat saidfabric whie it is dried.

[0012] Although the present invention is exemplified primarily as asystem which delivers one or more quaternary amine fabric-softeningagents, the invention is also intended to encompass a system which candeliver a wide variety of fabric-treating agents or fabric-treatmentagents. For example, an effective amount of one or more fabric-treatmentagents selected from the group consisting of anti-creasing agents,anti-soil agents, anti-static agents, bacteriostatic agents, brighteningagents, bodying agents, dyes, odor masking agents and fragrances, fiberemollients, finishing agents, germicides, lubricants, mildew- ormoth-proofing agents, shrinkage controllers, sizing agents, a starchcomposition, a water repellant composition, a composition for conferringspot resistance, and mixtures thereof can be uniformly distributedthroughout the present sheet, in conjunction with, or in place of, afabric-softening agent such as a quaternary amine fabric-softeningagent. When formulated in this manner, the present sheet is referred toas a “fabric-modifier” or “fabric-treatment sheet” instead of as a“fabric-softener” or “fabric-softener sheet.”

[0013] The present invention, including the above-described embodimentsand preferred versions thereof is more fully described in the followingdetailed discussion, wherein all percentages are by weight of thesoftening composition, unless otherwise noted.

DETAILED DISCUSSION OF THE INVENTION

[0014] A. Bag

[0015] The bags of the present invention may be formed from any flexiblematerial which exhibits sufficient thermal stability for use in therotary hot air dryer discussed above. Preferably, the bag will be formedfrom non-porous plastic film, non-woven fabric, and the like. Forexample, the outermost layer of the bag can be formed from polyethylene,polypropylene, polyamide or a multiple or layered complex comprisingsuch materials. The bag will further comprise vents, e.g.,mechanically-created pores or holes. The vents may also be in the formof “flaps” over pores or holes that will open and close in response tochanges in the vapor pressure inside the bag, to allow escape ofmoisture from the wet fabric articles as they dry.

[0016] Preferably the bags suitable for use in the present inventionwill have dimensions ranging from about 18″×23″ up to about 36″×40″. Themost preferred size of bag for use in the present invention range isfrom about 20″×28″ to about 26″×30″. These dimensions preferably resultin the bag having a surface area in the range of about 1120 in², andmost preferably from about 1120 in² to about 1560 in².

[0017] After use, the bag may be discarded, or if desired, it may beconstructed of a suitable material to allow repeated usage in aplurality of cleaning cycles.

[0018] B. Flexible Sheet

[0019] Fabric materials useful in the present invention to form theflexible sheet are woven or, preferably, non-woven fibers that aregenerally adhesively or thermally bonded. Fibrous sheets having a web orcorded fiber structure, or those which comprise fibrous mats in whichthe fibers are distributed haphazardly or in a random array can also beused. The fibers can be natural, such as wool, silk, jute, hemp, cotton,linen, sisal, or ramie; or synthetic such as rayon, cellulose ester,polyvinyl derivatives, polyolefins, polyamides or polyesters. Generally,any diameter or dernier of fiber is useful in the present invention. Thenon-woven cloth materials employed herein are not prone to tear orseparate when used, for example, in an automatic dryer, due to thehaphazard or random array of fibers in the non-woven material whichimpart excellent strength in all directions. Some examples of preferrednon-woven cloth material useful as substrates in the present inventioninclude 100% rayon sheets, known as Fabray® Nonwoven Fabric F-110 (40gm), available from Sterns Technical Textile Co. or as Brand #6129 fromScott Nonwovens; or 100% polypropylene sheets, known as NW-161,available from Kimberly Clark Co., Neenah, Wis.

[0020] C. Fabric Treatment Formulation

[0021] A fabric-treatment formulation useful in the invention can beprepared by mixing in the desired proportions a dispersing agent, water,an organic solvent, a softening or other treatment agent, a surfactantsuch as a nonionic or amphoteric surfactant, and stirring the mixtureuntil a homogeneous composition forms. Preferably, the organic solventsare added to the water in a suitable vessel with agitation and theapplication of external heating. At about 75-85° C., the dispersingagent, treatment agents, surfactants and any other adjuvants, such asfragrance and preservative, are added sequentially with continuousagitation.

[0022] 1. Fabric-Softening Agents

[0023] The present fabric-treatment formulation will preferably includean amount of one or more fabric-softening agents. Many usefulfabric-softening agents are known to the art, and are disclosed, forexample, in U.S. Pat. Nos. 3,936,538, 4,566,980, and 4,581,385,disclosures of which are incorporated by reference herein.Fabric-softening agents are useful in the fabric-treatment formulationin amounts from about 2.5-25 weight percent, and more preferably fromabout 10-20 weight percent. Cationic fabric-softening agents arepreferred for use in the fabric-treatment formulation.

[0024] One broad class of cationic softening or conditioning agentssuitable for use in the fabric-treatment formulation can be referred toas quaternary amines, or “quats.” These materials function to conditionthe dried fabrics and to reduce static cling and lint adherence. Thefabrics are “softened” in that their sheen, loft, and/or hand-feel isimproved by either subjective or objective evaluation. Additionally, anygiven softening agent or mixture thereof is selected so that it will notsignificantly stain or discolor the dried fabrics. Subclasses ofquaternary amines are well known to those of skill in the art andinclude the monomethyl trialkyl quaternaries, imidazoliniumquaternaries, dimethyl alkyl benzyl quaternaries, dialkyl dimethylquaternaries, methyl dialkoxy alkyl quaternaries, diamido amine-basedquaternaries and dialkyl methyl benzyl quaternaries preferably the“alkyl” moiety of these compounds is a (C₈-C₂₄) alkyl group and thequaternary(amine) is a chloride or methosulfate salt

[0025] It is sometimes preferable, for convenience, to define thesubclasses of aliphatic quaternary amines suitable for use in thefabric-treatment formulations structurally. For example, one usefulsubclass of aliphatic quaternary amines may be structurally defined asfollows:

(R)(R₁)(R₂)(R₃)N⁺X⁻

[0026] wherein R is benzyl, or lower(alkyl) benzyl; R₁ is alkyl of 10 to24, preferably 12 to 22 carbon atoms; R₂ is C₁₀-C₂₄-alkyl, C₁-C₄-alkl,or (C₂C₃)hydroxyalkyl, R₃ is C₁-C₄-alkyl or (C₂-C₃) hydroxyalkyl and Xrepresents an anion capable of imparting water solubility ordispersibility including chloride, bromide, iodide, sulfate andmethosulfate. Particularly preferred species of these aliphatic quatsinclude n-C₁₂-C₁₈-alkyl-dimethylbenzylammonium chloride (myrisalkoniumchloride), n-C₁₂-C₁₄-alkyldimethyl(ethylbenzyl) ammonium chloride(quaternium 14), dimethyl-(benzyl)ammonium chloride and mixturesthereof. These compounds are commercially available as the BTC seriesfrom Lonza, Fairlawn, N.J., e.g., BTC 2125M is a mixture ofmyrisalkonium chloride and quaternium-14, or as Variquat® B-343 fromSherex Chem. Co., Dublin, Ohio which is a dihydrogenated tallow methylbenzyl ammonium chloride. This class of quat is germicidal, and ispreferably used in combination with at least one of the other quatsdisclosed hereinbelow.

[0027] Other useful aliphatic quats include those wherein both R and R₁are (C₈-C₂₄) alkyl, e.g., theN,N-di-(higher)-C₁₀-C₂₄-alkyl-N,N-di(lower)-C₁-C₄(alkyl)-quaternaryammonium salts such as distearyl(dimethyl)ammonium chloride,dihydrogenated tallow(dimethyl)ammonium chloride,ditallow(dimethyl)ammonium chloride (Arquad® 2HT-75, Akzo Chemie McCook,Ill.), distearyl(dimethyl)ammonium methylsulfate anddi-hydrogenated-tallow(dimethyl)ammonium methyl sulfate (Varisoft® 137,Sherex).

[0028] Other useful quaternary ammonium antistatic agents include theacid salts of (higher(alkyl)-amido(lower)alkyl)-(dialkyl)-amines of thegeneral formula:

[(A(C═O)—Y—)—N(R₁)(R₂)(R₃)]⁺X⁻

[0029] wherein A is a C₁₄-C₂₄ normal or branched alkyl group, Y isethylene, propylene or butylene, R₁ and R₂ are individually H,C₁-C₄(lower)alkyl or(C₁-C₃)hydroxyalkyl or together form the moiety—CH₂—CH₂YCH₂—CH₂—, wherein Y is NH, O or CH₂; R₃ is the same as R₁ or isalso [A(C═O)Y—], and X is the salt of an organic acid. Compounds of thisclass are commercially available from Croda, Inc., New York, N.Y., asthe Incromate® series, e.g. Incromate® IDL[isostearamidopropyl(dimethyl)amine lactate], Incromate® ISML[isostearamidopropyl(morpholinium)lactate] and Incromate® CDP[cocamidopropyl(dimethyl)amine propionate], or as Incrosoft® T-75[Ditallowdiamido methosulfate (quaternium 53)].

[0030] Examples of preferred imidazolinium quaternaries include, but arenot limited to, (methyl-1-tallow-amido)ethyl-2-tallow imidazoliniummethyl sulfate, available commercially from Sherex Chemical Co. asVarisoft® 475; (methyl-1-oleylamido)ethyl-2-oleyl-imidazolinium methylsulfate, available commercially from Sherex Chemical Co. as Varisoft®3690; tallow dimethylammonium methosulfate, available commercially fromSherex Chemical Co. as Varisoft® 137; methyl bis(tallowamidoethyl)2-hydroxyethyl ammonium methyl sulfate availablecommercially from Sherex Chemical Co. as Varisoft® 222; tallowimidazolinium methosulfate (Incrosoft® S-75), and alkylimidazoliniummethosulfate (Incrosoft® CFI-75), both available from Croda, Inc., NewYork, N.Y.

[0031] Other useful amine salts are the stearyl amine salts that aresoluble in water such as stearyl-dimethylamine hydrochloride, distearylamine hydrochloride, decyl pyridinium bromide, the pyridinium chloridederivative of the acetylaminoethyl esters of lauric acid, lauryltrimethyl ammonium chloride, decylamine acetate andbis[(oleoyl)-(5,8)-ethanoloxy]-tallow(C₁₄-C₁₈)aminehydrogen phosphate(Necon® CPS-100) and the like.

[0032] 2. Other Fabric-Treating Agents

[0033] One or more additional fabric-treating agents may be used incombination with, or in place of, the fabric-softening agent, as long assuch additives do not interfere with the dispersal and softening and/orother treatment properties of the composition. When utilized in thismanner, about 2.5-25%, preferably about 5-15% of total fabric-treatingagents will be present in the aqueous dispersion from which the gelledsheet is formed.

[0034] Useful fabric-treating agents include the following:

[0035] Anti-creasing agents (also referred to as wrinkle-release agents)such as corn starch, polyvinyl acetate, and mixtures thereof;

[0036] Anti-soil agents (also referred to as soil-release agents) suchas the polyacrylic polyvinyl alcohol compositions described in U.S. Pat.No. 3,377,249;

[0037] Anti-static agents including liquid anti-static agents such asthe commonly-employed nonionic and anionic surfactants, as well ascationic amine surfactants such as tertiary or quaternary amines (manyof the quaternary amine fabric softening agents described hereinaboveprovide some anti-static effect); particulate anti-static agents such asaluminum oxide and stearates such as aluminum stearate; and mixturesthereof;

[0038] Bacteriostatic agents including alkyl dimethyl benzylammoniumchloride, dodecyl trimethyl ammonium chloride and mixtures thereof;

[0039] Brightening agents including bleaching agents such as thosedescribed in U.S. Pat. No. 4,532,063, sodium hypochlorite, calciumhypochlorite, hydrogen peroxide, sodium peroxide, sodium perborate, andpotassium permanganate; enzymes; and the like. Useful brightening agentsalso include optical brighteners suchas the disulfonated diaminostilbenecompounds disclosed in U.S. Pat. No. 2,612,501, and the triazolecompounds disclosed in U.S. Pat. No. 2,784,183;

[0040] Bodying agents such as carboxymethyl cellulose,hydroxyethylcellulose, starch, polyvinyl acetate and the like;

[0041] Dyes;

[0042] Fiber emollients including silicone fluids;

[0043] Finishing agents;

[0044] Fragrances such as rose oil, lavender, lilac, jasmine, vanilla,wisteria, lemon, apple blossom, or compound bouquets such as citrus,spice, aldehydic, woody, oriental, and the like;

[0045] Germicides include the halogenated salicylanilides,hexachlorophene, neomycin sulfate, benzalkonium quaternary compounds,and the like, as described in U.S. Pat. No. 3,650,816;

[0046] Lubricants such as polyoxyethylene sorbitan monolaurate andmethyl oleate;

[0047] Mildew-proofing or moth-proofing agents such as dialkylquaternary ammonium salts, e.g., distearyl dimethyl ammonium chloride;

[0048] Shrinkage controllers such as caustic soda used in mercerizingstrength, water-soluble resinous precondensates, and glyoxal; and

[0049] Sizing agents.

[0050] For a generic description of fabric treatment agents, see H.Speel and E. Schwarz, Textile Chemicals and Auxiliaries, 2d. ed.(Reinhold Pub. Corp. 1957).

[0051] 3. Surfactants

[0052] One or more surfactants are included in the presentfabric-treatment formulation, to assist in the formation of a uniformliquid dispersion, and to assist the dispersal of the formulation in thedryer. Nonionic surfactants or amphoteric surfactants are preferred foruse in the present invention since they are compatible with the cationicfabric treating agents and can also act as adjunct fabric softeners.Minor but effective amounts of certain anionic surfactants may also beuseful in the present invention to provide improved water-solubility andfaster dissipation of the sheets in the dryer.

[0053] Nonionic surfactants useful in the present formulations includethe condensation products of ethylene oxide with a hydrophobicpolyoxyalkylene base formed by the condensation of propylene oxide withpropylene glycol. The hydrophobic portion of these compounds has amolecular weight sufficiently high so as to render it water-insoluble.The addition of polyoxyethylene moieties to this hydrophobic portionincreases the water-solubility of the molecule as a whole, and theliquid character of the product is retained up to the point where thepolyoxyethylene content is about 50% of the total weight of thecondensation product. Examples of compounds of this type include certainof the commercially-available Pluronic® surfactants (BASF WyandotteCorp.), especially those in which the polyoxypropylene ether has amolecular weight of about 1500-3000 and the polyoxyethylene content isabout 35-55% of the molecule by weight, i.e., Pluronic® L-62.

[0054] Preferred nonionic surfactants include the condensation productsof C₈-C₂₂ alkyl alcohols with 2-50 moles of ethylene oxide per mole ofalcohol. Examples of compounds of this type include the condensationproducts of C₁₁-C₁₅ fatty alcohols with 3-50 moles of ethylene oxide permole of alcohol which are commercially available from Shell ChemicalCo., Houston, Tex., as, i.e., Neodol® 23-6.5 (C₁₂-C₁₃ fatty alcoholcondensed with about 7 moles of ethylene oxide), the PolyTergent® SLFseries from Olin Chemicals or the Tergitol® series from Union Carbide,i.e., Tergitol® 15-S-15, which is formed by condensing about 15 moles ofethylene oxide with a C₁₁-C₁₅ secondary alkanol; Tergitol® TMN-6, whichis the condensation product of about 6 moles of ethylene oxide withisolauryl alcohol (CTFA name: isolaureth-6), Incropol® CS-12, which is amixture of stearyl and cetyl alcohol condensed with about 12 moles ofethylene oxide (Croda, Inc.) and Incropol® L-7, which is lauryl alcoholcondensed with about 7 moles of ethylene oxide (Croda, Inc.).

[0055] Preferred nonionic fabric-softening agents also include (C₈-C₂₄)fatty acid amides, e.g., the monoamides of a mixture of arachidic andbehenic acid (Kenamide® B, Humko Chem. Co., Memphis, Tenn.), and themono- or di-alkanolamides of (C₈C₂₂) fatty acids, e.g., the diethanolamide, monoethanol amide or monoisopropanolamide of coconut, lauric,myristic or stearic acid, or mixtures thereof. For example, Monamide® Sis the monoethanol amide of stearic acid (Mona Industries, Inc.,Patterson, N.J.), and Monamine ALX-100S (Mona Industries), is a mixtureof the diethanol amide of cocoa fatty acid and the diethanol amide ofdodecylbenzene sulfonic acid. Monamide® CMS (Cocamide MEA; MonaIndustries, Inc., Paterson, N.J.) is also a useful member of this classof nonionic surfactants.

[0056] Other nonionic surfactants which may be employed include theethylene oxide esters of C₆-C₁₂ alkyl phenols such as(nonylphenoxy)polyoxyethylene ether. Particularly useful are the estersprepared by condensing about 8-12 moles of ethylene oxide withnonylphenol, i.e., the Igepal® CO series (GAF Corp., New York, N.Y.).

[0057] Other useful nonionics include the ethylene oxide esters of alkylmercaptans such as dodecyl mercaptan polyoxyethylene thioether, theethylene oxide esters of fatty acids such as the lauric ester ofpolyethylene glycol and the lauric ester of methoxypolyethylene glycol,the ethylene oxide ethers of fatty acid amides, the condensationproducts of ethylene oxide with partially fatty acid esters of sorbitolsuch as the lauric ester of sorbitan polyethylene glycol ether, andother similar materials, wherein the mole ratio of ethylene oxide to theacid, phenol, amide or alcohol is about 5-50:1.

[0058] Useful amphoteric surfactants are known to the art, e.g., asdisclosed in Marshall et al. (U.S. Pat. No. 3,936,538), the disclosureof which is incorporated by reference herein.

[0059] Useful anionic surfactants are known to the art, including sodiumcocoyl isothionate, commercially available as Jordapon® CI from MazerChemicals, Gurnee, Ill. The anionic surfactant may be optionally addedin minor but effective amounts, such that the total amount ofsurfactant, nonionic, amphoteric and anionic is from about 2 to about5%.

[0060] 4. Dispersing Agent

[0061] The present liquid fabric-treatment compositions will include anamount of a dispersing agent which is effective to uniformly distributethe ingredients of the formulation therein and to promote the release ofthe solvent and softening or treatment agent on the fabric articleswhile leaving no significant visible residue on the fabric. Thedispersing agent can also assist in thickening or gelling the liquiddispersions when they are cooled and applied to the non-woven sheet. Anydispersing agent or mixture of dispersing agents can be used whichstabilizes the fabric-treatment composition and assists in releasablyadhering it to the flexible sheet. Useful dispersing agents can includemodified starches, modified celluloses (CMC, HPMC), fatty acids and acidsalts, fatty alcohols, polysaccharide gums, and modified mineral clays,e.g., modified bentonite available commercially as Korthix™ H fromKaopolite, Inc, Union N.J. or Bentone Mass., commercially available fromRHEOX, Inc., Hightstown, N.J.

[0062] Preferred polysaccharide gums for use in the present compositionsinclude vegetable gums, such as the alkali metal salts of alginic acid(“alginates”), carrageenan (preferably kappa-carrageenan), pectin, guargum, and mixtures thereof. These “strong gums” re-gel from solution ordispersion to yield a continuous gel structure.

[0063] Other useful dispersing agents include polyvinylpyrrolidone,polyvinyl alcohol, polyacrylamides and polymeric organic waxes. Theuseful polymeric waxes include ethylene acrylate copolymers, ethyleneacrylic acid copolymers and polyethylene (e.g., oxidized polyethylenes).These materials are commercially available in the form of aqueousemulsions or dispersions, e.g., from Allied Chemical, Morristown, N.J.,as the A-C Copolymer and A-C Polyethylene series, such as A-C Copolymer540, A-C Copolymer 580 and A-C Polyethylene 617 and 629. Waxypolyethylene glycols (PEG) such as those of a molecular weight of about200 to 1700-2000 are preferred.

[0064] Other dispersing agents include the alkali earth metal, alkalineearth metal or ammonium salts of various naturally occurring orsynthetic fatty acids. Useful fatty acids may be selected from one ormore (C₈-C₂₂) fatty acids which incorporate 0-3 double bonds per fattyacid molecule, e.g., myristic acid, stearic acid, palmitic acid, lauricacid, behenic acid and the like. Alkali metal salts of fatty acids suchas steric acid are preferred. Commercially available salts of stearicacid can be used, e.g., the sodium stearate that is available from WitcoChem. Co. as Grade T-1. However, the stearate salt can be formed in situin the liquid dispersion, by neutralizing stearic acid with a base suchas an alkali metal hydroxide, e.g., LiOH, KOH, or NaOH, which may beadded to the dispersion as an aqueous solution.

[0065] Preferably, about 10-20% of the dispersing agent or agents willbe employed in the present fabric-treatment compositions.

[0066] 5. Organic Solvent

[0067] The present fabric-treatment compositions are formed bydispersing the fabric softening and/or treating agent and dispersingagent in a solvent system which can comprise water and an organicco-solvent or solvent mixture. Preferably, the organic solvent orsolvent mixture is non-toxic and water-miscible.

[0068] Most preferably, the major portion of the organic solvent will bea glycol ether. These materials are lower(alkoxy)- orlower(alkoxy)lower(alkoxy)-ethers of ethanol or isopropanol. Someexamples of preferred glycol ethers are available under the trade namesArcosolv® (Arco Chemical Co.) or Cellosolve®, Carbitol®, or Propasol®(Union Carbide Corp.), and include, e.g., butylCarbitol®,hexylCarbitol®, methylCarbitol®, and Carbitol® itself,(2-(2ethoxy)ethoxy)ethanol. The choice of glycol ether can be readilymade by one of skill in the art on the basis of its volatility,water-solubility, wt-% of the total dispersion and the like.Pyrrolidinone solvents such as N-methyl-2-pyrrolidinone (M-Pyrol®) or2-pyrrolidone (2-Pyrol®) can also be used. Minor amounts of alkanolssuch as isopropanol or n-butanol can also be included.

[0069] Alcohols which can be employed as co-solvents include liquidpolyethylene glycols, i.e., polyethylene glycol-200, 300, 400 or 600,wherein the suffixed numbers indicate the approximate molecular weightof the glycol. Other useful co-solvents include other alcohols, forexample: (a) lower(alkanols), such as ethanol, isopropanol, andn-butanol; (b) ketones such as acetone and methyl ethyl ketone; (c)C₂-C₄ polyols, such as a diol or triol, e.g., ethylene glycol, propyleneglyol, glycerol or mixtures thereof or (d) hydrocarbon solvents such asisoparaffinic solvents (Isopar K).

[0070] The organic solvent is present in the fabric-treatnentcomposition in an amount from about 2 to about 75 weight percent, morepreferably in an amount of from about 30 to about 50 weight percent andmost preferably from about 35 to about 40 weight percent.

[0071] 6. Water

[0072] Depending upon the nature of the other components present in thefabric-treatment composition and their respective amounts, when water ispresent, the water content of the composition can range from about 10-55weight percent, preferably from about 15-25 weight percent. Generally,sufficient water is employed to completely suspend the dispersing agentand other components to insure the preparation of a homogeneousfabric-treatment composition upon cooling.

[0073] 7. Formulation

[0074] Therefore, the fabric treatment formulations used to form thepresent impregnated sheets will comprise, by weight, about 30-50%water-miscible organic solvent, preferably about 35-40% of a glycolether or pyrrolidinone solvent; about 10-30%, preferably about 15-25%total water; about 2.5-25%, preferably about 15-20% of one or morefabric treatment agents; about 10-20% of a dispersing agent, about 2-5%of a surfactant, and optionally, a minor but effective amount offragrance, e.g. <2%.

[0075] D. Formation of Impregnated Sheet

[0076] The fabric-treatment composition can be applied onto the flexiblesheet, e.g., by casting the dispersion onto the flexible sheet, as bydipping, spraying, or brushing the dispersion onto the surface, or bypouring an amount of the fabric-treatment formulation on the flexiblesheet and then “drawing down” the formulation with a metal rod or bar.The finished sheet may be perforated for division into smaller units, orsimply cast into its end-use size. The individual sheets or a stripcomprising a plurality of sheets separated by perforations may bepackaged, e.g., using protective release sheets, in an appropriatedispensing unit. Following a cooling period, the finishedfabric-treatment non-woven sheets are preferably packaged in moistureimpermeable packaging, e.g., in foil, a foil-plastic film or afoil-treated paper composite envelope.

[0077] The following examples further illustrate the present inventionand preferred embodiments thereof. It is to be understood, however, thatthese examples are for illustrative purposes only and are not intendedto limit the scope of the specification or claims thereof in any way.

EXAMPLE I

[0078] Formulation of Fabric-Treatment Composition

[0079] A 1500 ml beaker was charged with 219.8 g distilled water. Whilemixing, 287.9 ml of polyethylene glycol (PEG-200) was added. 100 mL of2-(2-ethoxy-ethoxy)ethanol (Carbitol LG® , Union Carbide Corp.) wasadded and the reaction mixture was heated to 85° C. While maintainingthe mixture at 85° C., 120 mL of sodium stearate was added and themixture stirred until all components were in solution. 21 g of cocamideMEA (Monamid CMA, Mona Industries, Inc., Paterson, N.J.) was addedslowly into the beaker until entirely in solution. Fourteen grams ofoleth-20 (Lipocol O-20) was then melted and added to the beaker,followed, sequentially at five minute intervals, by the addition of143.4 g of quaternium-27 (Varisoft 475), 13.6 g of melted Varisoft 137,and 40.3 g Varisoft 222. Ten g modified bentonite (Bentone Mass.) wasadded slowly to this mixture until fully dispersed, followed by 15 gKorthix H. also stirred until fully dispersed. Finally, 15.00 gfragrance (3539-4113R) was added and the entire mixture stirred 15minutes to ensure uniformity.

EXAMPLE II

[0080] Sheet Impregnation with Fabric Softener Formulation

[0081] The mixture prepared in Example I was applied to a 10″×10″non-woven sheet (Crown Textile #2927) to form the fabric-treatmentnon-woven, impregnated sheet. Specifically, the non-woven sheet wasplace on a metal plate and placed in a constant temperature oven (60°C.) along with a metal rod for drawing the product across the sheet.When the plate, sheet and rod were at 60° C., they were removed from theoven and 100 g of the fabric treatment composition prepared in Example 1was poured onto the sheet close to the rod. The rod was subsequentlyquickly drawn down the length of the sheet, resulting in the uniformcoating of the sheet.

[0082] Upon cooling, a finished, impregnated, fabric-treatment sheet wasobtained, the surface of which was impregnated and stably coated withthe fabric-treatment formulation.

[0083] The invention has been described with reference to variousspecific and preferred embodiments and techniques. However, it should beunderstood that many variations and modifications may be made whileremaining within the spirit and scope of the invention.

What is claimed is:
 1. A fabric-softening system adapted for containmentand softening a fabric article, said device comprising a bag whichcomprises an opening incorporating a fastening system so that the bagcan enclose a moistened fabric article and a flexible sheet having aneffective amount of a liquid fabric-softener formulation releasablyabsorbed thereinto, wherein said bag is formed of a flexible, ventedmaterial which is not substantially damaged upon exposure to agitationand to a temperature effective to cause the release of saidfabric-softening formulation from said non-woven sheet.
 2. The system ofclaim 1 wherein the fabric-softener formulation consists essentially ofabout 30-50% water-miscible organic solvent, about 15-25% water; about2.5-25% of one or more fabric softening agents; about 10-20% of adispersing agent, and about 2-5% of a surfactant.
 3. The system of claim2 wherein the organic solvent comprises at least one glycol ether. 4.The system of claim 2 wherein the surfactant comprises a nonionicsurfactant.
 5. The system of claim 2 wherein the surfactant comprises anamphoteric surfactant.
 6. The system of claim 2 wherein the dispersingagent comprises a fatty acid, a modified mineral clay, or mixturesthereof.
 7. The system of claim 6 wherein the dispersing agent comprisesan alkali metal salt of stearic acid or a modified mineral clay.
 8. Thesystem of claim 1 wherein said fastening system of said bag consists ofpress-studs, clips, a zipper, a Velcro® strip, a Ziplock® seal oropposed strips of resealable adhesive.
 9. The system of claim 1 whereinsaid flexible vented material consists of polypropylene, polyethylene orpolyamide.
 10. The system of claim 1 wherein said sheet is a woven ornon-woven textile sheet.
 11. A fabric-treatment system adapted forcontainment and treatment of a fabric article, said system comprising abag which comprises an opening incorporating a fastening system so thatthe bag can enclose a moistened fabric article and a flexible sheethaving an effective amount of a liquid fabric-treatment formulationreleasably absorbed thereinto, wherein said bag is formed of a flexiblevented material which is not substantially damaged upon exposure toagitation and to a temperature effective to cause the release of saidfabric-treatment formulation from said flexible sheet.
 12. The system ofclaim 11 wherein the fabric-treatment formulation consists essentiallyof about 30-50% water-miscible organic solvent, about 15-25% water;about 2.5-25% of one or more fabric-treatment agents; about 10-20% of adispersing agent, and about 2-5% of a surfactant.
 13. The system ofclaim 12 wherein the fabric-treatment agent is chosen from the groupconsisting of anti-creasing agents, anti-soil agents, anti-staticagents, bacteriostatic agents, brightening agents, bodying agents, dyes,fiber emollients, finishing agents, fragrances, germicides, lubricants,mildew-proofing or moth-proofing agents, shrinkage controllers, sizingagents and mixtures thereof.
 14. The system of claim 12 wherein theorganic solvent comprises at least one glycol ether.
 15. The system ofclaim 12 wherein the dispersing agent comprises an alkali metal salt ofstearic acid or a modified mineral clay.
 16. The system of claim 11wherein said fastening system of said bag consists of press-studs,clips, a zipper, a Velcro® strip, a Ziplock® seal or opposed strips ofresealable adhesive.
 17. The system of claim 11 wherein said flexiblevented material consists of polypropylene, polyethylene or polyamide.18. A process for softening or otherwise treating a fabric article witha fabric-treatment formulation, said process comprising: (a) placing amoistened fabric article into a device, said device comprising a bagcomprising an opening which incorporates a reversible fastening systemso that the bag can enclose said fabric article, with a flexible sheethaving an effective amount of a fabric-treatment composition releasablyabsorbed thereinto, said fabric-treatment composition consistingessentially of a liquid vehicle selected from the group consisting ofwater, a water-miscible organic solvent and mixtures thereof; aneffective amount of a dispersing agent, and about 2.5-25% of afabric-softening agent or other fabric treatment agent; (b) closing saidfastening system to form said bag into a closed system comprising saidmoistened fabric article and said flexible sheet; (c) tumbling saidclosed system in a rotary clothes dryer at an elevated temperature, sothat the fabric-treatment formulation is released from said non-wovensheet, and contacts said article so as to effectively soften orotherwise treat said article as it dries; and (d) opening said fasteningsystem and removing the softened and/or treated fabric article from thebag.
 19. The process of claim 18 wherein the tumbling is carried out atabout 40-95° C.
 20. The process of claim 18 wherein the tumbling iscarried out for about 15-45 minutes.
 21. The process of claim 18 whereinsaid fabric article is an article of clothing.